Asphalt compositions comprising hydrogenated and aminated vegetable oil, asphalt products made from such asphalt compositions, and the methods of making and using such compositions and products

ABSTRACT

An additive comprising a hydrogenated and aminated vegetable oil, products made thereof including asphalts, asphalt pellets, asphalt paving, roofing materials, adhesives, glues, inks, coatings, sealants, paints, color dispersants, polymers, transfer inks, and other products made thereof, and methods of making and using said compositions and products. Methods of modifying asphalt include contacting asphalt with a hydrogenated and aminated vegetable oil.

RELATED APPLICATION DATA

This application claims priority from and is a continuation in part of U.S. patent Ser. No. 14/600,844, filed Jan. 20, 2015, the specification of which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to asphalt compositions, to asphalt products made from such asphalt compositions, and to methods of making and using such compositions and products. In another aspect, the present invention relates to asphalt compositions which may be readily applied to surfaces using common equipment and techniques, to asphalt surfaces formed therefrom, and to methods of making and using such compositions and surfaces. In even another aspect, the present invention relates to asphalt compositions using for making thin and ultrathin paving layers, and to method for making and using such compositions and layers. In still another aspect, the present invention relates to asphalt compositions useful in making a non-tracking, hot applied tack coat for bonding two layers of hot mix asphalt together, to non-tracking, hot applied tack coats, to multiple layer surfaces in which the top coat is a non-tracking, hot applied tack coat, and to methods of making and using the foregoing. In yet another aspect, the present invention relates to asphalt compositions comprising a high Pen (i.e., flexible) asphalt, and to products made therefrom, and to methods of making and using such compositions and products. In even still another aspect, the present invention relates to asphalt compositions comprising a lower rotational viscosity asphalt (especially in combination with maintaining a higher softening point), and to products made therefrom, and to methods of making and using such compositions and products. In even yet another aspect, the present invention relates to asphalt compositions comprising a more ductile asphalt to provide products made therefrom some capability of stretching or movement under traffic loading or weather related expansion and contraction, and to products made therefrom, and to methods of making and using such compositions and products. In still even another aspect, the present invention relates to asphalt compositions comprising an asphalt having a sufficient elastic recovery to allow products made therefrom to recover after traffic load had passed or weather related fatigue, and to products made therefrom, and to methods of making and using such compositions and products. In still yet another aspect, the present invention relates to asphalt compositions comprising an asphalt having a lower bond strength, to provide some flexibility to products made therefrom and allow then to move/give way under traffic loading and temperature sweeps (warm to cold e.g., summer/winter and cold front weather), and to products made therefrom, and to methods of making and using such compositions and products. In even another aspect, the present invention relates to use of vegetable oil that is both hydrogenated and aminated for modifying asphalt, to methods of modifying asphalt by the addition of such hydrogenated and aminated vegetable oil, to asphalt compositions comprising hydrogenated and aminated vegetable oil, and to asphalts products comprising hydrogenated and aminated vegetable oil, and to methods of making and using such compositions and products. In even another aspect, the present invention relates to asphalt paving compositions comprising hydrogenated and aminated vegetable oil, and to asphalt pavement comprising hydrogenated and aminated vegetable oil, and to methods of making and using such compositions and products. In still another aspect, the present invention relates to hot-mix and warm mix asphalt paving compositions comprising hydrogenated and aminated vegetable oil, and to hot mix and warm mix asphalt pavement comprising hydrogenated and aminated vegetable oil, and to methods of making and using such compositions and products. In yet another aspect, the present invention relates to asphalt roofing compositions comprising hydrogenated and aminated vegetable oil, and to asphalt roofing products and roofs comprising hydrogenated and aminated vegetable oil, and to methods of making and using such compositions and products. In even still another aspect, the present invention relates to methods of preparing roofing asphalt materials without the need for blowing, and to products made thereby. In even yet another aspect, the present invention relates to methods of upgrading asphalts by the addition of hydrogenated and aminated vegetable oil, and to compositions and products made therefrom. In yet even another aspect, the present invention relates to asphalt compositions in which hydrogenated and aminated vegetable oil is utilized to reduce the necessary polymer levels in the asphalt composition and to methods of making an using such, and to products made therewith. In yet still another aspect, the present invention relates to glues, paints, sealants, coatings, color pigment dispersions, and inks comprising hydrogenated and aminated vegetable oil, and to methods of making an using such, and to products made therewith. In a further aspect, the present invention relates to blown asphalt or asphalt pellets comprising hydrogenated and aminated vegetable oil, and to methods of making an using such, and to products made therewith. In even a further aspect, the present invention relates to production of polyvinylchloride or polyethylene utilizing a hydrogenated and aminated vegetable oil, and to methods of making an using such, and to products made therewith.

2. Description of the Related Art

U.S. Pat. No. 5,069,578, issued Dec. 31, 1991, to Bense et al., discloses a Bonded Friction Course (“BFC”) road asphalt system, known as the NOVACHIP process which utilizes a specialized “Spray Paver” machine to apply a thick layer of polymer modified tack coat immediately before a thin gap-graded Hot Melt Adhesive (“HMA”) asphalt layer is applied. This polymer modified tack coat wicks into the new gap graded mix by displacement and water vaporization. The tack coat provides a degree of adhesion or bonding between the layers and also acts to reduce slippage and sliding of the layers relative to other layers in the pavement structure during use or due to wear and weathering of the pavement structure. The thick application of the tack coat further seals minor cracks in the existing surface layer and forms a strong bond between the new HMA layer and the existing pavement.

Unfortunately, the NOVACHIP bonded friction course system can be prohibitively expensive due to the requirement that the specialized “Spray Paver” machine be used. In the 2011, each spray paver machine was reported to cost almost $500,000, and many paving contractors and state and county transportation agencies cannot justify the expense. However, without the use of the NOVACHIP Spray Paver, the thick layer of emulsified polymer modified tack coat used in a bonded friction course system would be very difficult to work with. The thick layer of emulsion tack coat would have a very slow cure rate, resulting in unacceptable delays and also tracking of the tack coat layer. Tracking occurs when the tack or bonding coat is picked up on the tires or tracks of vehicles traveling over the coated surface. Where this occurs, the asphalt compositions often are tracked onto other pavement surfaces causing disruption to the surrounding area. This tracking also reduces the effectiveness of the tack coat by displacing a portion of the intended volume from the area awaiting a new pavement layer.

Insufficient adhesion between a new layer of pavement and an existing base course, a previously laid pavement layer, or a prepared pavement surface can cause pavement separation and cracking during construction of the structure, as well as subsequent failures and premature deterioration of the pavement structure and/or surface. Such conditions often require costly repairs, can cause damage to vehicles traveling on the surface and may cause dangerous traffic conditions threatening damage to property and injury to vehicles and passengers.

To overcome the need for the specialized NOVACHIP “Spray Paver” machine, U.S. Patent Publication No. 20110206455, published Aug. 25, 2011, by Blacklidge, discloses a method of applying building a pavement structure using a polymer modified hot-applied tack coat that is applied with conventional asphalt distributors without the need for any specialized machinery. This polymer modified tack coat is non-adhesive at ambient temperatures, and, thus, also non tracking. The tack is applied while hot, but cools quickly. The subsequent application of hot mix asphalt results in a superior bond between the asphalt layer and the tack layer. It is particularly well suited to bonded friction course applications since it removes the necessity of specialized spray paving machinery and allows the use of conventional asphalt distributors and pavers.

Other asphalt related art includes the following patents and publications.

U.S. Pat. No. 4,198,177, issued Apr. 15, 1980, to Ray, Jr., et al., discloses methods and apparatus for repair of asphalt surfaces. The invention provides an improvement for those systems for repairing asphalt surfaces that include an emulsion tank, air pressure source, emulsion heating source, pneumatic tools and a vehicle having a fluid cooled engine and a utility body for containing asphalt repairing material. Specifically, the improvement disclosed is an emulsion tank removably mounted on said vehicle for containing a water soluble, air cured, sealer-bonding agent, an air compressor mounted on and driven by said vehicle engine, an air storage tank removably mounted on said vehicle and coupled to said compressor and pressurized thereby, means for selectively coupling air from said pressurized tank to said pneumatic tools and said emulsion tank and means coupling said vehicle cooling fluid to said emulsion tank for heating said emulsion to a usable temperature whereby certain of said pneumatic tools may be selectively driven by said compressed air in said storage tank to trim a damaged asphalt surface, spray emulsion over said trimmed are under pressure from said compressed air tank, and compact said asphalt repairing material into said trimmed and sealed area thereby repairing said damaged asphalt area.

U.S. Pat. No. 4,762,565, issued Aug. 9, 1988, to Graf, discloses an open-graded asphalt paving composition comprising about 80 to 97% by weight of an open-graded aggregate and about 3 to 20% asphalt, said composition being formed by successively mixing two asphalt-containing emulsions A and B with said aggregate wherein: emulsion A comprises about 40 to 75% by weight of a soft asphalt having a viscosity in the range of 50 to 1000 centistokes at 210° F. and 0.25 to 5% by weight of a emulsifier, and water as a continuous phase of said emulsion to make up 100% by weight; and emulsion B comprises about 40 to 75% by weight of a hard asphalt having a penetration 5 to 25 dmm at 77° F. and 0.25 to 5% by weight of a emulsifier, and water as a continuous phase of said emulsion to make up 100% by weight.

U.S. Pat. No. 4,836,857, issued Jun. 6, 1989, to Hopkins discloses asphalt additive compositions which comprise (A) a metallic organic strength improving compound and (B) an anti-strip compound. The metal of said metallic organic compound is selected from the group consisting of manganese, cobalt, copper, vanadium, molybdenum, cerium, iron, nickel, lead, zirconium, barium, calcium and zinc. The preferred metal is manganese. The anti-strip compound is designed to reduce water-induced damage to asphalt paving mixtures.

U.S. Pat. No. 5,735,634, issued Apr. 7, 1998 to Ulrich et al., discloses a road finisher, which is used for simultaneously applying at least two surface layers comprises a chassis, a travelling mechanism, at least two premix containers arranged on said chassis, a lateral distributor associated with the respective premix container and adapted to have material supplied thereto via a conveyor path extending in the chassis, and lateral outriggers attached to the chassis as well as a dragged road-surface applying device used for applying a surface layer and arranged on said outriggers, all road-surface applying devices being high-compaction road-surface applying screeds for re-compaction-free application of a surface layer, and each high-compaction road-surface applying screed constituting a rear screed, when seen in the direction of movement, which is constructed as a high-compaction road-surface applying screed which is adapted to be used for applying and compacting concrete. In the method of applying surface layers by use of such a road finisher, the surface layers are applied one immediately after the other and in one operation in such a way that each first surface layer is highly compacted during application to such a degree that re-compaction is no longer necessary and each following surface layer is applied to the highly-compacted surface layer and then, in turn, highly compacted to such a degree that re-compaction is no longer necessary.

U.S. Pat. No. 5,769,567, issued Jun. 23, 1998 to Durand et al., discloses a process and a machine for forming a bonding layer for bonding a bituminous coated material layer on a support. The process includes application of a surface-active agent on the support, application of a bituminous emulsion on the surface-active agent on the support, and application of a breaking agent on the bituminous emulsion to form the bonding layer. A road-type coating made by the process and, therefore, including such a support layer, a bonding layer on the support, and a bituminous coated materials layer on the bonding layer. To perform the process, a machine includes a frame, a displacement mechanism on the frame, a bituminous-emulsion spreader on the frame, a surface-active agent applicator on the frame, and a breaking agent applicator on the frame.

U.S. Pat. No. 6,444,258, issued Sep. 3, 2002 to Terry, discloses a method and apparatus of treating a pavement surface, including the steps of: applying a layer of bituminous sealant at a predetermined temperature and application rate on the pavement surface; applying a layer of bituminous emulsion at a predetermined temperature and application rate on the first of bituminous sealant, wherein a thermal reaction occurs between the bituminous sealant and the bituminous emulsion so as to accelerate a material break and cure time for said layers; and, providing a layer of aggregate particles at a predetermined application rate on the layers of bituminous sealant and bituminous emulsion during the thermal reaction. The steps of the method are performed successively along a particular direction of advance at a rate which permits them to be accomplished within a predetermined time period. Additional steps of compacting the layers and/or applying an asphalt layer thereon may also be performed.

U.S. Patent Publication No. 20070141241, published Jun. 21, 2007 by Blacklidge, a method for bonding together an existing substrate layer and a pavement layer, such that a strong adhesive bond is formed by using a tack coat, provided by an asphalt emulsion, in between the layers as the bond coat. The tack coat layer is a low-tracking coating which cures quickly such that the pavement layer may be applied to the substrate, hours to days after the emulsion is applied to the substrate. The asphalt emulsion comprises at least a first phase of from about 30% to about 70% of an asphalt composition, about 30% to about 70% water, and about 0.1% to about 3.0% emulsifying agent, stabilizer and/or additives, or 0.1% to about 30% if polymeric or other additives are also included.

U.S. Pat. No. 7,503,724, issued Mar. 17, 2009 to Blacklidge, discloses a method for bonding together an existing substrate layer and a pavement layer, such that a strong adhesive bond is formed by using a tack coat, provided by an asphalt emulsion, in between the layers as the bond coat. The tack coat layer is a low-tracking coating which cures quickly such that the pavement layer may be applied to the substrate, hours to days after the emulsion is applied to the substrate. The asphalt emulsion comprises at least a first phase of from about 30% to about 70% of an asphalt composition, about 30% to about 70% water, and about 0.1% to about 3.0% emulsifying agent, stabilizer and/or additives, or 0.1% to about 30% if polymeric or other additives are also included.

U.S. Patent Publication No. 20090169901, published Jul. 2, 2009, by Blacklidge, discloses a method for bonding together an existing substrate layer and a pavement layer, such that a strong adhesive bond is formed by using a tack coat, provided by an asphalt emulsion, in between the layers as the bond coat. The tack coat layer is a low-tracking coating which cures quickly such that the pavement layer may be applied to the substrate, hours to days after the emulsion is applied to the substrate. The asphalt emulsion comprises at least a first phase of from about 30% to about 70% of an asphalt composition, about 30% to about 70% water, and about 0.1% to about 3.0% emulsifying agent, stabilizer and/or additives, or 0.1% to about 30% if polymeric or other additives are also included.

U.S. Patent Publication No. 20090182074, published Jul. 16, 2009 by Scholten, discloses an asphalt binder comprising 85 to 97.5 parts by weight of a bitumen and 16 to 2.5 parts by weigh of a polymer composition, wherein the polymer composition comprises: (i) from 2 to 8, preferably from 3 to 6 parts by weight of a styrenic block copolymer having at least two blocks of monovinylaromatic hydrocarbon (A) and at least one block of a conjugated diene (B), wherein the block copolymer composition has a vinyl content of at least 25% by weight, preferably from 25 to 40% by weight, based on the total diene content; (ii) from 0 to 5, preferably from 1 to 3 parts by weight of a styrenic di-block copolymer having one block of monovinylaromatic hydrocarbon (A) and one block of a conjugated diene (B); and (iii) from 0.5 to 3, preferably from 1 to 2.5 parts by weight of an ethylene-vinyl acetate copolymer, wherein the weight ratio of (i)+(ii):(iii) is from 2:1 to 6:1, preferably from 3:1 to 4:1. In addition, an asphalt mix is provided comprising 2 to 8 parts by weight of the asphalt binder of the present invention and 98 to 92 parts by weight of gap-graded aggregate or open-graded aggregate material. Furthermore, a porous pavement is claimed, produced from the open or gap-graded mixes, by compacting the asphalt mix mentioned above.

U.S. Patent Publication No. 20130154985, published Jun. 6, 2013, by Blacklidge et al., discloses a method of making an asphalt composition containing large quantities of ground tire rubber. Over 20% GTR by weight can be used in the asphalt composition without the GTR settling out. The method comprises a series of heating and blending and using a GTR stabilizer.

U.S. Pat. No. 8,840,717, issued Sep. 23, 2014, to Naidoo et al., discloses an additive package for warm-mix asphalt formulations for the pavement of road surfaces, said additive package comprising a) surfactant component, and b) an asphalt rheology modifying component, wherein said asphalt rheology modifying component comprises at least one of a i) a wax component and ii) a resin component. The invention also relates to a warm mix asphalt having improved compaction at lower temperatures, and to a pavement made from said warm mix asphalt.

Referring back to the asphalt compositions, products and methods of the '455 Publication, they utilize low Pen value (i.e. stiffer) asphalts, and these stiffer asphalts when utilized in trackless-type tacks, may perform poorly in thin pavements. Such hard Pen binders are becoming increasingly difficult to source and further, they are very variable in quality from refinery to refinery as well as crude oil source variations. Further, while asphalts of the '455 Publication are far more sprayable than the prior art NOVACHIP asphalts, there is still room for improvement in the sprayability of the '455 Publication asphalts that can be affected by having a lower rotational viscosity asphalt. Even further, the asphalts of the '455 Publication (as tested in the Example section below) have ductility of zero, meaning absolutely no capability of stretching or movement under traffic loading or weather related expansion and contraction. Still further, the asphalts of the '455 Publication (as tested in the Example section below) have an elastic recovery of zero, meaning will absolutely not allow the Tack Coat to recover after traffic load had passed or weather related fatigue. Finally, the asphalts of the '455 Publication has high bond strengths. Interestingly, the higher bond strength is not necessarily better since as the bond becomes too rigid and will not move/give way under traffic loading and temperature sweeps (warm to cold eg summer/winter and cold front weather). Therefore the asphalts of the '455 Publication also have room for improvement with a lower bond strength to provide/allow more movement.

Thus, in spite of the advances in the prior art, there is still a need in the art for improved asphalt compositions, improved asphalt products, and methods of making and using such compositions and products.

Thus, there is a need in the art for asphalt compositions comprising a high Pen (i.e., flexible) asphalt, and to products made therefrom, and to methods of making and using such compositions and products.

There is another need in the art for asphalt compositions comprising a lower rotational viscosity asphalt (especially in combination with maintaining a higher softening point), and to products made therefrom, and to methods of making and using such compositions and products.

There is even another need in the art for asphalt compositions comprising a more ductile asphalt to provide products made therefrom some capability of stretching or movement under traffic loading or weather related expansion and contraction, and to products made therefrom, and to methods of making and using such compositions and products.

There is still another need in the art for asphalt compositions comprising an asphalt having a sufficient elastic recovery to allow products made therefrom to recover after traffic load had passed or weather related fatigue, and to products made therefrom, and to methods of making and using such compositions and products.

There is yet another need in the art for asphalt compositions comprising an asphalt having a lower bond strength, to provide some flexibility to products made therefrom and allow then to move/give way under traffic loading and temperature sweeps (warm to cold e.g., summer/winter and cold front weather), and to products made therefrom, and to methods of making and using such compositions and products.

Thus, there is a need in the art for methods of increasing asphalt softening point without the need for blowing, and to asphalts compositions and products formed from such asphalt.

There is another need in the art for methods of providing asphalt compositions comprising a higher softening point while suffering only a moderate decrease in Pen value, and to asphalts compositions and products formed from such asphalt.

The is even another need in the art for methods of providing asphalt compositions comprising a higher softening point that do not suffer oxidative aging as with blowing methods, and to asphalts compositions and products formed from such asphalt.

There is even another need in the art for methods of up grading asphalt compositions without resort to blowing, and to asphalts compositions and products formed from such asphalt.

These and other needs in the art will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide for improved asphalt compositions, improved asphalt products, and methods of making and using such compositions and products.

It is another object of the present invention to provide for asphalt compositions comprising a high Pen (i.e., flexible) asphalt, and to products made therefrom, and to methods of making and using such compositions and products.

It is even another object of the present invention to provide for asphalt compositions comprising a lower rotational viscosity asphalt (especially in combination with maintaining a higher softening point), and to products made therefrom, and to methods of making and using such compositions and products.

It is still another object of the present invention to provide for asphalt compositions comprising a more ductile asphalt to provide products made therefrom some capability of stretching or movement under traffic loading or weather related expansion and contraction, and to products made therefrom, and to methods of making and using such compositions and products.

It is yet another object of the present invention to provide for asphalt compositions comprising an asphalt having a sufficient elastic recovery to allow products made therefrom to recover after traffic load had passed or weather related fatigue, and to products made therefrom, and to methods of making and using such compositions and products.

It is even still another object of the present invention to provide for asphalt compositions comprising an asphalt having a lower bond strength, to provide some flexibility to products made therefrom and allow then to move/give way under traffic loading and temperature sweeps (warm to cold e.g., summer/winter and cold front weather), and to products made therefrom, and to methods of making and using such compositions and products.

It is another object of the present invention to provide for methods of increasing asphalt softening point without the need for blowing, and to asphalts compositions and products formed from such asphalt.

It is another object of the present invention to provide for methods of providing asphalt compositions comprising a higher softening point while suffering only a moderate decrease in Pen value, and to asphalts compositions and products formed from such asphalt.

It is another object of the present invention to provide for methods of providing asphalt compositions comprising a higher softening point that do not suffer oxidative aging as with blowing methods, and to asphalts compositions and products formed from such asphalt.

It is another object of the present invention to provide for methods of up grading asphalt compositions without resort to blowing, and to asphalts compositions and products formed from such asphalt.

These and other objects will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.

According to one embodiment of the present invention, there is provided a paving composition comprising an aminated wax and an asphalt cement with a pen value greater than 50 dmm at 25° C.

According to another embodiment of the present invention, there is provided a paving composition comprising an aminated wax and an asphalt cement.

According to even another embodiment of the present invention, there is provided a pavement structure comprising: a substrate pavement layer; and a tack coat applied to the substrate pavement layer, wherein the tack coat comprises an asphalt cement with a pen value greater than 50 dmm at 25° C.

According to still another embodiment of the present invention, there is provided a pavement structure comprising: a substrate pavement layer; and, a tack coat applied to the substrate pavement layer, wherein the tack coat comprises an aminated wax and an asphalt cement with a pen value greater than 50 dmm at 25° C.

According to yet another embodiment of the present invention, there is provided a pavement structure comprising: a substrate pavement layer; and, a tack coat applied to the substrate pavement layer, wherein the tack coat comprises an asphalt cement and an aminated wax.

According to even still another embodiment of the present invention, there is provided a method of forming a pavement structure. The method includes at least applying a tack coat to a substrate pavement layer, wherein the tack coat comprises an asphalt cement with a pen value greater than 50 dmm at 25° C.

According to even yet another embodiment of the present invention, there is provided a method of forming a pavement structure. The method includes at least applying a tack coat applied to a substrate pavement layer, wherein the tack coat comprises an aminated wax and an asphalt cement with a pen value greater than 50 dmm at 25° C.

According to yet even another embodiment of the present invention, there is provided a method of forming a pavement structure. The method includes at least applying a tack coat to a substrate pavement layer, wherein the tack coat comprises an asphalt cement and an aminated wax.

Various sub-embodiments of any of the above embodiments further include: wherein the rejuvenator comprises tall oil; compositions and/or tack coat further comprising a polymeric component; wherein the aminated wax is plant oil derived; wherein the tack coat comprises a softening point of 135° C. or higher; wherein the tack coat comprises a rotational viscosity at 150° C. of less than 600 cps; wherein the tack coat comprises a rotational viscosity at 160° C. of less than 400 cps; wherein the tack coat comprises ductility values at 25° C. of greater than 1 cm; wherein the tack coat comprises elastic recovery values at 25° C. of greater than 1%; wherein the tack coat comprises a bond strength in the range of about 100 psi to about 300 psi; wherein the tack coat further comprises an aminated wax derived from castor oil; further comprising an asphalt layer applied to the tack coat; and/or further comprising allowing the tack layer to cool and applying an asphalt layer to the tack coat, the asphalt layer heated to a temperature sufficient to increase the adhesive properties of the tack coat. It should be understood that any of the further details as described herein may be included in any of the embodiments of the invention.

According to a further embodiment of the present invention, there is provided an asphalt composition comprising a hydrogenated and aminated vegetable oil and an asphalt cement.

According to a further embodiment of the present invention, there is provided a method of making an asphalt composition comprising contacting an asphalt with a hydrogenated and aminated vegetable oil.

According to a further embodiment of the present invention, there is provided a pavement structure comprising a substrate pavement layer, and a tack coat applied to the substrate pavement layer, wherein the tack coat comprises an asphalt cement and a hydrogenated and aminated vegetable oil.

According a further embodiment of the present invention, there is provided a pavement structure comprising at least one layer comprising asphalt and a hydrogenated and aminated vegetable oil.

According to a further embodiment of the present invention, there is provided a method of modifying an asphalt comprising contacting the asphalt with a hydrogenated and aminated vegetable oil to form a modified asphalt

According to a further embodiment of the present invention, there is provided a roofing shingle comprising asphalt and a hydrogenated and aminated vegetable oil.

According to a further embodiment of the present invention, there is provided a method of making a warm mix additive comprising contacting asphalt binder with a hydrogenated and aminated vegetable oil at temperatures above 250° F.

According to a further embodiment of the present invention, there is provided a method of sealing a surface, comprising applying to the surface, a sealant comprising asphalt and a hydrogenated and aminated vegetable oil.

According to a further embodiment of the present invention, there is provided a sealant comprising asphalt, a hydrogenated and aminated vegetable oil, and a solvent.

According to a further embodiment of the present invention, there is provided a method of forming a blow asphalt, the method comprising providing an asphalt mixture comprising asphalt and a hydrogenated and aminated vegetable oil, and blowing the asphalt mixture to form blown asphalt.

According to a further embodiment of the present invention thee is provided a method of modifying a blown asphalt comprising contacting the blown asphalt with hydrogenated and aminated vegetable oil.

According to a further embodiment of the present invention, there is provided a method of pelletizing asphalt, the method comprising, providing an asphalt mixture comprising asphalt and a hydrogenated and aminated vegetable oil, and pelletizing the asphalt mixture to form asphalt pellets.

Even further embodiments of the present invention relate to adhesives, glues, paints, sealants, coatings, color pigment dispersions, and inks comprising hydrogenated and aminated vegetable oil, and to methods of making an using such, and to products made therewith.

Even further embodiments of the present invention relate to production of polyvinylchloride or polyethylene utilizing a hydrogenated and aminated vegetable oil, and to methods of making an using such, and to products made therewith.

These and other embodiments of the present invention will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a picture showing for example 1, Milled (right) and Unmilled (left) Substrate Samples.

FIG. 2 is a picture showing for example 1, substrate samples at 0.08 gallon/square yard application rate for example 1.

FIG. 3 is a picture showing for example 1, 0.08 (left) and 0.13 (right) gallon/square yard application rates—for milled substrate samples.

FIG. 4 is a picture showing for example 1, tack coat bond strength breaking head

FIG. 5 is a picture showing for example 1, tack bond strength samples after testing.

FIG. 6 is a picture showing for example 1, tack coat interface after testing—milled substrate.

FIG. 7 is a data table for Example 2 showing the effect of additive on softening point and Pen value of PG 67-22 asphalt binder.

FIG. 8 is a data table for Example 3 showing use of the additive of the present invention in the production of BUR Roofing Grades from standard refinery asphalt streams and demonstrates that blowing is not necessary.

FIG. 9 is a data table for Example 4 showing use of hydrogenated and aminated castor wax to produce built-up-roofing grades or binders and thus eliminating the need for blowing asphalt.

FIG. 10 is a data table for Example 5 showing results for the reduction in blow time evaluation of 60%, 70% and 80% blown binders plus additives—filled and unfilled coatings evaluation.

FIG. 11 is a data table for Example 6 showing performance of the use of hydrogenated and aminated castor oil wax in roofing shingles coatings.

FIG. 12 is a data table for Example 7 showing the effect of the additive of the present invention on PG Grade Bump, Viscosity Reduction above 270° as well as as Compaction Aid for Stiff and High Viscosity Mixes.

FIG. 13 is a data table for Example 8 demonstrating that deeply hydrogenated castor oil will not produce the same effect in asphalt binder as the deeply hydrogenated castor oil that is also aminated.

FIG. 14 is a data table for Example 9 demonstrating the UV light stability enhancing effect of the hydrogenated and aminated castor oil.

FIG. 15 is a data table for Example 10 also demonstrating the UV light stability enhancing effect of the hydrogenated and aminated castor oil.

FIG. 16 is a data table showing Tensile Strength Ratio (TSR) for a control and samples with 0.5% and 1% additive of the present invention conducted according to Test Method AASHTO T283.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides for asphalt compositions, provides for asphalt products made therefrom, and provides for methods for making and using such compositions and products. Products of the present invention include tack coats, and multiple layer pavement structures made therefrom. Tack coats are thin layers of asphalt product that are used in the construction or re-facing of roads and highways. This type of product is used to help the layers of asphalt laid down as part of the road building process to bond together with more efficiency. As a result, the highway or road is able to hold up under constant use for longer periods of time, making it easier to maintain the road properly.

Some non-limiting embodiments of the present invention provides asphalt compositions useful for creating a bonded friction course pavement structure that does not require the use of specialized machinery for its application. Specifically, the present invention may employ conventional asphalt distributors (i.e., tank trucks having a spray bar as a non-limiting example), to place a hot-applied, tack coat having the property after cooling of being non-adhesive at ambient temperatures. The present invention tack coat layer is applied while hot, at temperatures greater than 212° F. in a liquid form, and may be allowed to cool to ambient temperatures. At ambient temperatures, the tack coat is non-tracking and non-adhesive. However, when it comes into contact with a new hot mix asphalt layer, the tack coat becomes adhesive, again. Thus, the present invention provides resulting pavement structures with improved strength compared to other known paving systems.

As used herein, “ambient temperature” is any temperature that is typically used in paving applications, with temperatures generally set by governmental regulations/specification, or in the case of private parties by contract there between. Very commonly, paving is typically only performed at temperatures greater than about 40° F., 50° F. or 60° F. As for an upper limit, “ambient temperature” will typically be less than 120° F., 130° F. or 140° F. Thus, ranges for “ambient temperatures” will generally be in the range of greater than about 40° F., 50° F. or 60° F. ranging up to about 120° F., 130° F. or 140° F.

Some non-limiting embodiments of present invention provide (i) modified asphalt compositions that comprise asphalt and an aminated wax, or (ii) comprise asphalt having a pen value greater than 50 dmm, or (iii) comprise asphalt and aminated wax with the asphalt having a pen value greater than 50 dmm (pen values throughout are at 25° C. unless otherwise indicated). All of these embodiments may further include a rejuvenator, and/or a elastomeric polymer.

For the asphalt compositions of the present invention, the Needle Pen value is an important property that determines the hardness of the tack coat upon spray out onto the surface substrate and which spray out should not be too soft (defeat Trackless property) nor should it be too hard (to cause embrittlement and cracking under weather and traffic load related fatigue).

In the practice of some embodiments of the present invention, generally any suitable asphalt may be modified with the aminated wax regardless of the pen value of the asphalt.

Other embodiments will be limited to asphalts having a certain pen value that allow the asphalt to wet the surface substrate and bond with the old pavement and new layer paved over it. If the Pen is too low (hard) there will be no wetting and bonding (too dry) in addition to lack of flexibility. As non-limiting examples, suitable asphalts include those with pen values greater than 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 65, 70, 75, 80, 90 or 100 dmm. Suitable ranges of pen values for such asphalts will generally range between any two of 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 65, 70, 75, 80, 90 or 100 dmm. Additional suitable ranges of pen values for such asphalts will generally range to/from any two of 50.01, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 65, 70, 75, 80, 90 or 100 dmm. Non-limiting examples of suitable ranges includes pen values between 50 and 80, 90 or 100 dmm, or greater than 50 and up to 80, 90 or 100 dmm. Other non-limiting examples of suitable ranges include from 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or 60 to 65, 70, 75, 80, 90 or 100 dmm. Still other non-limiting examples includes pen values from 55 to 80 dmm.

While the invention is not so limited to this asphalt, a commercially available grade suitable for use in the present invention includes Pen Grade 60/70 asphalt that has a Pen value in the range of 60 to 70 as the grade name describes.

Certain embodiments of the present invention provide for asphalt compositions modified with one or more aminated waxes having a softening point of at least 125° C. and above. As non-limiting examples, suitable aminated waxes may have a softening point of at least 125° C., 130° C., 135° C., 140° C., 145° C., 150° C., 160° C., or 170° C. Suitable aminated waxes may have a softening point in the range of between or to/from any two of the following 125° C., 130° C., 135° C., 140° C., 145° C., 150° C., 155° C., 160° C., 165° C., or 170° C.

Suitable aminated waxes useful in the present invention will obviously have amine functionality so that it interacts with the asphalt binder and surfaces it is intended to bond (i.e., the old and new layer). These useful aminated waxes have certain special performance characteristics, and may impart any or all of the following upon asphalt. First, a suitable wax may be an active material interacting with the old and new aggregate. Second, a suitable wax may make the asphalt binder more ductile, that is, for example, it may increase the ductility at 25 C from 55 cm or so to over 80 cm and even over 100 cm. In the practice of the present invention, this ductility increase is important as it will allow for a shift between the old and new layers under traffic load and with differential contraction of the pavement layers with temperature (summer/winter). Third, a suitable wax may lower the viscosity of the asphalt binder so that spray out will be easy and controllable within fine limits. Without being limited by theory, applicant believes this is accomplished by lowering the surface tension of the asphalt binder. Fourth, a suitable wax makes the asphalt have a high set point, i.e. it is liquid (sprayable) at 150 C or higher but will be solid at 140 C/284 F making it “Quick Set” for driving upon to pave the new layer without sticking to the paver wheels. Fifth, a suitable wax may raise the softening point of the binder to above 250° F. Sixth, a suitable wax allows for the asphalt composition to be easily produced in any mixing apparatus without the need for high shear equipment.

As is well known, waxes include synthetic waxes, petroleum waxes, and those derived from any number of plants and animals, and such waxes may find utility in the present invention. Generally, waxes suitable for use in the present invention are the ones with longer carbon chains and that have a sufficient ester functionality. Vegetable oils are especially useful for making aminated waxes suitable for the present invention. As non-limiting examples, aminated waxes derived from linseed oils, castor oils, rapeseed oils, soy oils, jatropha oils, just to name a few, are useful in the present invention. In the present invention, the vegetable oils may first be hydrogenated prior to being aminated. As a non-limiting example, castor oil may be first deeply hydrogenated to a melt point of 85 C to 90 C and then aminated to melt point of 125 C to 160 F (preferably 135 C to 145 C). A non-limiting commercially available examples of such an aminated castor oil wax is EcoGreen SPA, marketed by Shamrock M.E.D. LLC and which has a melt point in the range of 135° C. to 145° C., Iodine Value of 4 max and an acid value of 5 mg KOH/g an with an average molecular weight of 1030. More discussion of the hydrogenation and amination embodiments are discussed below, and are further illustrated by Examples 7-15. Other non-limiting embodiments of the present invention utilize a wax compound(s) derived from compounds having a triglyceride structure, or from compounds that are glyceryl triricinoleates.

Various non-limiting embodiments of the present invention provide a non-tracking, polymer modified tack coat that is non-adhesive at ambient temperatures that may be applied utilizing conventional asphalt distributors (i.e., tank trucks having a spray bar as a non-limiting example). In the practice of the present invention, the hot-applied tack coat is heated until it is liquid and sprayable and, then, sprayed on the pavement to create the thick layer. Typically this tack coat is applied at the rate of 0.04 to 0.8 gals/yd² for a conventional HMA overlay, or 0.09 to 0.18 gals/yd² for a Bonded Friction Course. Once applied, the layer of tack coat cures hard to the touch in seconds to form a non-tracking surface. Cracks that may exist in existing pavement are filled by this thick layer, thus sealing the surface. A hot-mix asphalt layer can, then, be placed over the tack coat layer almost instantly after the tack coat layer has cooled. Formulation methods and application methods as taught and described in U.S. Patent Publication No. 2011/0206455 may be utilized in the practice of the present invention, and that publication is herein incorporated by reference for all that it teaches.

As the tack coat of the present invention cools, it becomes non-adhesive, and, therefore, non-tracking. Vehicles can drive over this layer without fear of the tack coat sticking to the tires of the vehicles. When the hot-mix asphalt layer is applied on top of the tack coat, the heat of the HMA layer causes the tack coat to liquefy, and this liquefied membrane is wicked into the HMA layer by displacement. At the higher temperatures of the hot mix layer, the tack coat is extremely adhesive, allowing it to form a strong structural bond with the OGFC or other hot mix asphalt layer. As the tack coat of the present invention cools, the bond with the hot mix asphalt layer becomes stronger. However, the tack coat of the present invention retains its flexibility.

It should be appreciated that the present invention trackless tack coat is particularly useful in Open Graded Friction Course, Bonded Friction Course, and thin overlay mixes where the material was previously applied with specialized distributors, such as “Spray Pavers.” However, using the claimed method only a conventional distributor and paver are required. As a result, the methods disclosed are available to all contractors and government agencies that do not want to purchase a proprietary or specialized machine.

The disclosed method may use any tack coat formulation that has the desired properties of being adhesive only at higher temperatures, but not at ambient temperatures. The tack coat can be made by blending a high Pen value asphalt (i.e., pen value greater than 50) and/or with aminated wax and/or other additives as discussed above.

Some embodiments of the asphalt compositions of the present invention are further modified with a rejuvenator that functions to maintain the binder rejuvenation and bond strength during life of pavement. The rejuvenator utilized in the present invention is generally a tall oil product such as any of those disclosed in U.S. Pat. No. 8,608,845, which patent is hereby incorporated by reference. This rejuvenator serves to rejuvenate the old pavement and activate the aged binder it contains to bond with the membrane layer sprayed, and also to continue the rejuvenation process and bonding between the old pavement and membrane layer and the new pavement and the membrane layer. This process will be ongoing during the life of the pavement to give ongoing good adhesion. The rejuvenator will also provide ongoing Low Temperature Flexibility as the pavement ages. Any similar rejuvenator that is used in the rejuvenation of aged Reworked Asphalt Pavement (RAP) and/or Reworked Asphalt Shingles (RAS) may also be embodied in this invention as non-limiting Rejuvenators. The function of the Rejuvenator is to disperse the asphaltenes so formed with aging of the asphalt binder and to keep the reformation of such asphaltenes in check.

A commercially available non-limiting example of a suitable rejuvenator is Hydrogreen S rejuvenator, a reacted mixture of Tall Oil and selected vegetable oils. commercially produced and marketed in the USA by PVS (Meridian) Inc., under U.S. Pat. No. 8,608,845. It should be understood that any suitable rejuvenator may be utilized, and certainly any reacted mixtures of tall oil and vegetable oil(s) may be utilized.

For the following descriptions of the possible weight percent content of the asphalt compositions, it should be understood that after accounting for all of the possible additives, the balance of the asphalt composition will be asphalt as described herein. Generally, the asphalt component will comprise at least 60, 70, 80, 90, 95 or more weight percent of the composition, based on the total weight of the composition.

Asphalt compositions of the present invention may include aminated wax(es), that when present will comprise in the range of between or to/from any two of the following 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15 or 20 percent by weight of the total composition. As non-limiting examples, suitable ranges include 2% to 10% and 4% to 8% (weight percent based on total weight of composition). The aminated wax generally provides Softening Point enhancement as well as wetting out of the surface substrate and active bonding with the substrate.

Asphalt compositions of the present invention may include tall oil composition rejuvenators, that when present will comprise in the range of between or to/from any two of the following 0.2, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 percent by weight of the binder composition. As non-limiting examples, suitable ranges include 0.5% to 5% and 2% to 3% (weight percent based on total weight of the binder composition). The rejuvenator generally provides effective rejuvenation and substrate wetting out.

Asphalt compositions of the present invention may include elastomeric polymer(s), that when present will comprise in the range of between or to/from any two of the following 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 percent by weight of the total composition. As non-limiting examples, suitable ranges include 0.5% to 4% and 1% to 2.5% (weight percent based on total weight of composition). The elastomeric polymer generally provides for required flexibility. Non-limiting examples of suitable elastomeric polymers are styrene butadiene styrene (SBS), styrene butadiene rubber (SBR), terpolymers, acrylic polymers, ethyl vinyl acetate, natural rubber, ground tire rubber or any polymer that imparts flexibility to the tack coat in cold climate conditions and under repeated traffic loading stresses.

For the asphalt compositions of the present invention, rotational viscosity is important for accurate and consistent spray out and even and consistent coverage of the surface substrate without plugging of the spray nozzles and without stringing out upon rapid cooling upon emitting from the spray nozzles. Generally, the desirable rotational viscosity in summer conditions (spray out temperature of 150° C./302° F.) is in the range of between or to/from any two of the following 90, 100, 110, 125, 150, 175, 200, 225, 250, 275, 300, 400, 500 and 600 cps. As non-limiting examples, for a spray out temperature of 150° C./302° F., a rotational viscosity in the range of 110 cps to 300 cps or in the range of 125 cps to 250 cps. In cooler Spring and Fall climates (spray out temperature of 160° C./320° F.) the desirable rotational viscosity range is in the range of between or to/from any two of the following 80, 90, 100, 110, 120, 130, 150, 170, 190, 200, 250, 300, 350 and 400 cps. As non-limiting examples, for a spray out temperature of 160° C./320° F., a rotational viscosity in the range of 80 cps to 200 cps or in the range of 90 cps to 190 cps.

For the asphalt compositions of the present invention, Softening Point is an important property that controls the set point (ie transition from molten state to solid state) of the Tack Coat on the surface substrate. Therefore a high softening point is desirable in the range of between or to/from any two of the following 200° F., 210° F., 220° F., 230° F., 240° F., 250° F., 260° F., 270° F., 280° F., 290° F., or 300° F. As non-limiting examples, softening points in the range of about 220° F./104° C. to 280° F./138° C. or in the range of 250° F./121° C. to 270° F./132° C.

For the asphalt compositions of the present invention, Bond Strength of any formed tack coat is an important property, and the Bond Strength should not be so high as to render the composition “glassy” and susceptible to cracking. High Bond strength, up to a point is good for adhesion over the life of the pavement and endured traffic load and temperature fatigue cycles. However, a degree of flexibility in the bond is essential to permit some pliability and movement under such pavement fatigue stresses and strains described above. If such flexibility is not present the Tack Coat bond will crack and the integrity of the pavement will be compromised and it will fail prematurely. Therefore extremely high Bond Strengths such as that exhibited by some commercial products being too brittle will crack and work against the concept of bonding and rather cause pavement failure. Therefore in the practice of the present invention, there needs to be a good balance between bonding and flexibility as can be provided by the asphalts of the present invention. Thus, some embodiments of the present invention provide asphalt compositions in which the resultant tack coat (for thin and ultrathin pavement overlays) will have a bond strength that will not exceed 300 psi as a safety margin against such cracking potential. Certainly, the bond strength will meet common minimum bond strengths (generally 100 psi).

For the asphalt compositions of the present invention, ductility is an important property, and is a measure of how the Tack Coat will stretch or become ductile to give way under repeated traffic loading and/or when the pavement expands and contracts with changing ambient temperatures (ie. summer, winter, temperature sweeps and, cold fronts approaching). The asphalts of the present invention provide superior tack coats that are very ductile and have a great measure of “give” under repeated traffic loading and unloading on the pavement as well as with weather related expansion and contraction. Products of the present invention will have ductility values at 25° C. of greater than 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 125, or 150 cm.

For the asphalt compositions of the present invention, elastic recovery is an important property, and is a measure of how the Tack Coat will stretch and recover after being subjected to repeated traffic loading and unloading. Such recovery is essential for the short and long term integrity of the pavement to prevent pavement cracking. As can be seen from the data in the Examples, Tack Coats made from '455 Publication type asphalt have zero Elastic Recovery and will absolutely not allow the Tack Coat to recover after traffic load had passed or weather related fatigue. To the contrary, tack coats of the asphalt compositions of the present invention has a sufficient level of Elastic Recovery which will allow for the Tack Coat to recover under such conditions. Products of the present invention will have elastic recovery values at 25° C. of greater than 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 25 or 30%.

In some embodiments of the present invention, there is the combination of the higher softening point for the composition as described above, combined with the low viscosity as described above that provides improvements such as quick setting.

In other embodiments of the present invention, there is the combination of the higher softening point for the composition as described above, combined with the Pen Value as described above.

In generally, conventional wisdom limits the use of trackless tack in cool weather. The compositions of the present invention would appear to buck conventional wisdom and still be useful in cool weather. Additionally, the compositions of the present invention are believed to be suitable for use in thin (i.e., 1-2 inches thick) and ultrathin (i.e., less than 1 inch thick) paving applications. And while the compositions are useful in warm/hot weather, they are also believed to be useful in cool/cold weather, including weather in which the ambient temperature at the paving site during the paving application is less than any of the following, or in a range between any 2 of the following, or in a range from/to any 2 of the following: 60 F, 55 F, 50 F, 45 F, 40 F, 35 F, 30 F, 25 F, and 20 F.

Hydrogenated and Aminated Embodiments

Some embodiments of the present invention require hydrogenating the additive prior to amination. While it is believed that any vegetable oil is suitable for use in such hydrogenation and amination embodiments, it will be illustrated by reference to castor oil.

Castor oil is produced from farmed and harvested castor seeds and has been produced for decades and is widely known and used in applications such as food additives, personal health care products, pharmaceuticals as well as in Industrial applications such as production of nylon, polyols, paints, carbon black dispersion, automotive and Industrial greases, paints and coatings, etc. Castor oil is unique in chemical structure with three carbon chains (triglyceride structure), hydroxyl groups and un-saturation and is a glyceryl triricinoleate. It is thus also believed that waxes useful in the present invention may be derived from other compounds with the same or similar structure, including those that comprise a triglyceride structure.

Castor Oil is also used as a starting material for the production of a range of low and high melt point waxes. Firstly the castor oil is deeply hydrogenated and then also can subsequently be aminated and both processes are capable of producing a range of melt point waxes from 40° C. to 150° C. and above.

A number of asphalt properties may be significantly influenced and enhanced by the use of an aminated and hydrogenated castor oil, and again it is believe that other vegetable oils are also useful, such as linseed oils, castor oils, rapeseed oils, soy oils, Jatropha oils, just to name a few. Various non-limiting embodiments of the present invention include compositions of asphalt and the additive of the present invention, methods of modifying asphalt to change a property, and to asphalt products, mixes, and layers made thereof and methods of making such products.

Softening Point. Modifying asphalt with an aminated and hydrogenated vegetable oil additive will achieve significantly higher Softening Point in asphalt binder and by far superior to any known waxes used in asphalt modification including Fischer-Tropsch Waxes, Polyethylene Waxes, Polypropylene Waxes, etc. This ability to increase the Softening Point by magnitudes and at comparatively low dosage levels is not known in the prior art. This eliminates the need for the blowing of asphalt binder to raise the softening point, a positive environmental benefit. Various non-limiting embodiments of the present invention include, modified asphalt with increased softening point, methods of reducing softening point of asphalt by addition of the additive of the present invention, and asphalt products, mixes, and layers made thereof and methods of making such products.

Penetration. Modifying asphalt with an aminated and hydrogenated vegetable oil additive results in the Penetration being reduced with incremental additive dosage, but levels off at Pen 15 to 20 unlike Fischer-Tropsch Waxes that drastically reduce Pen value. Roofing applications generally cannot tolerate such drastic Pen reductions since the Roofing Shingle will harden even further through aging on the Roof to become crack susceptible. Various non-limiting embodiments of the present invention include, modified asphalt with a leveled off Pen value in the range of 15 to 20, methods of leveling off the Pen value in the range of about 15 to 20 by addition of the additive of the present invention, and asphalt products, mixes, and layers made thereof and methods of making such products.

Viscosity. Modifying asphalt with an aminated and hydrogenated vegetable oil additive reduces the viscosity of the asphalt binder and especially that of the modified asphalt binders at typical asphalt working temperatures (250° F. to 330° F.). This is a benefit in energy savings in the storage, handling and mixing and applications in both Paving and Roofing products manufacture. The sharp viscosity drop above 250° F. makes the additive useful for compaction of difficult mixes (high polymer content, sticky polymers, dense graded mixes and stone mastic asphalt mixes) in the Hot Mix mode as well as in the Warm Mix mode. This benefit is further accentuated by the “slip/glide” properties of the additive as a lubricant in the asphalt and asphalt mix working temperatures. Various non-limiting embodiments of the present invention include, modified asphalt with a reduced viscosity, methods of reducing the viscosity of asphalt by addition of the additive of the present invention, and asphalt products, mixes, and layers made thereof and methods of making such products.

Adhesion. Modifying asphalt with an aminated and hydrogenated vegetable oil additive increase the adhesive properties of the asphalt binder. Because of its structure as described above, when castor oil is deeply hydrogenated and then aminated, the resultant reacted molecule will have a significantly elevated melt point. Deeply hydrogenated castor oil has a melt point of around 88° C. to 90° C. and when subsequently aminated the melting point is further elevated to 135° C. to 145° C. and even higher. Please note however, that it is possible to make other melt points by changing the mole ratio of the reactant components and we can make 90 C to over 160 C melt point products. Specifically if the mole ratio of the amine is increased then the melt point of the aminated wax is decreased and conversely if the mole ratio of the amine is decreased, then the melt point of the aminated wax is reduced. At the same time the hydrogenated and aminated wax formed has a high degree of flexibility arising from the triglyceride structure. The inventors believe that in addition to castor oil, other oils or compounds having a triglyceride structure are also useful in the present invention. The amine functionality contributes to the adhesive bond with substrates much like amine anti-strip agents do in forming an active bond with the substrate. This adhesive property is important for all asphalt applications and to whatever surfaces asphalt is applied (eg wood concrete, stones, steel, aluminum, paper, cardboard, plastic, all metals, etc.). Thus, some non-limiting embodiments of the present invention provide for asphalt having improved adhesion, methods of making an asphalt with improved adhesion by addition of the additive of the present invention, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

This adhesion property is also very important when forming asphalt mixes containing aggregate. As shown by data below, the addition of the additive of the present invention provides for much improved adhesion between the asphalt binder and the aggregate in the asphalt mix. The data clearly shows that the additive provides active adhesion of binder onto aggregate surfaces. Thus, some non-limiting embodiments the present invention provide for asphalt binder-aggregate mixes having improved adhesion between the asphalt binder and aggregate, methods of making an asphalt mix with improved adhesion between the asphalt binder and aggregate, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

Lubricity at molten temperatures. Modifying asphalt with an aminated and hydrogenated vegetable oil additive increases lubricity. The castor oil triglyceride structure imparts a unique “wrap around” lubricity and maximizes the surface contact points to maximize the lubricity effect. This property is important for Warm Mix and the Compaction effect in maximizing density. Thus, some non-limiting embodiments the present invention provide for asphalt having increased lubricity at molten temperatures, methods of making an asphalt having increased lubricity at molten temperatures by addition of the additive of the present invention, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

Ductility. Modifying asphalt with an aminated and hydrogenated vegetable oil additive will enhance the ductility of the asphalt. When the additive is combined with the residual base oils in the asphalt binder, the additive significantly enhances the ductility of the asphalt binder. Such residual base oils are considered undesirable as they soften the binder and also the oils flush to the surface on hot days and with afternoon rains makes the pavement “slick” like driving on glass causing loss of control and accidents. Thus, the additive provides a way of neutralizing those residual oils while enhancing the ductility of the asphalt. Thus, some non-limiting embodiments the present invention provide for asphalt having enhanced ductility, methods of making an asphalt having enhanced ductility by addition of the additive of the present invention, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

Slip/Skid Resistance at ambient temperatures. Modifying asphalt with an aminated and hydrogenated vegetable oil additive provides the asphalt with slip resistance and skid resistance. Basically, the high molecular weight of the additive combined with the superior oil absorbing and retention property, makes the additive function as a Slip Resistant and Skid Resistant component when added to asphalt binder and/or mix and Floor Polishes (not asphalt based but wax and polymer based). Thus, some non-limiting embodiments the present invention provide for asphalt having enhanced slip/skid resistance, methods of making an asphalt having enhanced skip/skid resistance by addition of the additive of the present invention, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

Flexibility. Modifying asphalt with an aminated and hydrogenated vegetable oil additive imparts flexibility. This is an important property for Roofing Rolls, Waterproof construction paper, waterproof aluminum sheeting, etc. The additive, because of the triglyceride structure described above, imparts the degree of flexibility required for such applications. Thus, some non-limiting embodiments the present invention provide for asphalt having enhanced flexibility, methods of making an asphalt having enhanced flexibility by addition of the additive of the present invention, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

Solvent Resistance. Modifying asphalt with an aminated and hydrogenated vegetable oil additive provides solvent resistance, for example to Jet Fuel, Diesel, Gasoline & Chemical Solvents. Generally, the additive in combination with polymers and/or natural asphalts (eg, Gilsonite and Trinidad Lake Asphalt) and petroleum asphalt binder, a Solvent Resistant coating may be produced. This ability is derived from the unique molecular structure that has a multi-contact and reactive points with other polymers and materials to form a resistant film coating. Thus, some non-limiting embodiments the present invention provide for asphalt having enhanced solvent resistance, methods of making an asphalt having enhanced solvent resistance by addition of the additive of the present invention, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

UV Light Stability. Modifying asphalt with an aminated and hydrogenated vegetable oil additive provides UV light stability. Since the additive has a much higher melt point compared to the asphalt binder, it co-crystallizes with the asphalt binder and other additives first to form a layer to shield from UV Light as protection. While hydrogenation and aminization is described by reference to castor oil, other oils would be hydrogenated and aminated similarly. Further, the present invention is not meant to be limited to any particular hydrogenation and/or aminiation method(s). The hydrogenation and amination methods described below are provided as merely non-limiting alternatives of hydrogenating and aminating, and it should be kept in mind that other hydrogenation and amination methods may be utilized in the practice of the present invention. Thus, some non-limiting embodiments the present invention provide for asphalt having enhanced UV light stability, methods of making an asphalt having enhanced UV light stability by addition of the additive of the present invention, and to and asphalt products, mixes, and layers made thereof and methods of making such products.

Castor oil may be hydrogenated utilizing any suitable method, as the present invention is not limited to any particular hydrogenation method. As a non-limiting example, castor oil may be hydrogenated in the presence of nickel catalyst in a medium pressure reactor under specified conditions of temperature, pressure and catalyst concentration. After hydrogenation, the catalyst may be separated by filtration and the molten product may be passed through a flaking machine to obtain the final product in the form of flakes for easy handling and storage in polyethylene lined bags. Hydrogenation of castor oil may be carried out at relatively low temperature and pressure to preserve the hydroxyl group. While other process conditions may be utilized, the inventors are pleased with the results that are obtained at 130° C. plus or minus 5° C. at a pressure of 1.5 atmospheres with 0.2% by weight of nickel catalyst. Certainly, the invention is not meant to be limited to those conditions, and it is believed that other catalysts and processing parameters may be used to produce unique derivatives. Simple double bond hydrogenation at 140° C. in the presence of Raney nickel catalyst produces glyceryl (12 hydroxystearate), having a melting point of 86° C. to 88° C.

A non-limiting example of a hydrogenated castor oil is described below. Certainly, other hydrogenated castor oils having one or more parameters outside of the description may be suitable.

Properties Typical Parameters Acid value, mg KOH/g 5 max Iodine value, mg/g 4 max. Hydroxyl value, mg KOH/g 155 min. Saponification value, mg KOH/g 180 min. Melting point, ° C. 86

Next, the hydrogenated oil obtained by the above described method, or any method for that matter is then aminated. It should be understood that any suitable amination method may be utilized in the present invention, as the present invention is not limited to any particular amination method. As a non-limiting method, the deeply hydrogenated castor oil (wax flakes) made as described above but which may be obtained from any hydrogenation process, may then be aminated with hexamethylene diamine in the mole ratio in the range of about 0.8:1.0 to 1.2:1.0, although any suitable ratio may be utilized. The reaction is carried out under stirring and inert (nitrogen blanket) conditions in the temperature range of 180° C. to 240° C. depending on feedstock quality. The reaction may be monitored by measuring the acid value and amine value of the reacted material and typical values for both these parameters is less than 10. After reaching the desired amine and acid values, the product is poured onto a cooling band and flaked and bagged.

Other non-limiting examples of suitable alternative acids useful to hydrogenate castor oil are ricinoleic acid, stearic acid, palmitic acid, myristic acid and their mixtures. Other non-limiting examples of alternative amines are ethylene diamine, p-phenylene diamines, meta-xylene diamine and their mixtures. The present invention is not intended to be limited to any particular acid or amine, and it should be understood that many other acids or amines beyond those listed herein may be utilized.

A non-limiting example of a hydrogenated then aminated castor oil is described below. Certainly, other hydrogenated then aminated castor oils having one or more parameters outside of the description may be suitable.

Properties Typical Parameters Acid value, mg KOH/g 5 Amine value, meq/g 5 Hydroxyl value, mg KOH/g 155  Melting point, ° C. 135 to 145

Some embodiments of the present invention relate to the use of hydrogenated aminated castor oil wax in the melt range of 80° C. to 145° C. and higher in asphalt applications as well as in hot melt adhesives, thermal transfer inks, inks and coatings (solvent based, water based and powders), PVC extrusion, PVC molding, PP extrusion, PP molding, PE extrusion and PE molding applications.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in a number of applications/products, some examples of which are discussed below, with castor oil being a non-limiting example of a suitable vegetable oil.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of a drive-on-tack coat.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production paper coatings, that is, waterproofing and construction paper coatings, and paper coatings for insulating rolls and sheeting.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of woven fiber and fabric coatings, and provides flexibility and waterproofing properties.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of roofing shingles laminating adhesive. The additive plus asphalt binder produces a low viscosity (easy to apply and consistent application) laminating adhesive with superior bond strength. There is no need for hard Pen or modified asphalt, as it is produced from straight run refinery asphalt that is commonly available from any asphalt plant. Also, such an adhesive is simple to blend and does not require high shear equipment.

Regarding the roofing shingles laminating and tab seal adhesives and further, this concept claims that both types of adhesive may be replaced by one combined product using, for example, base asphalt binder PG 64-22. As an example, a non-limiting formulation for such an adhesive will be 90% PG 64-22 binder plus 0.25% to 2% Rejuvenator plus 4% to 8% of the Additive.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of roofing shingles tab seal adhesive. The additive plus asphalt binder produces a low viscosity (easy to apply and consistent application) tab seal adhesive with superior control set time. There is no need for hard Pen or modified asphalt as it is produced from straight run refinery asphalt that is commonly from asphalt plants. Also, such an adhesive is simple to blend and does not require high shear equipment.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of a combined one pack roofing shingles tab seal and laminating adhesive. A single pack product that is a combined Laminating and Tab Seal Adhesive in one has been successfully formulated using the concepts above. A non-limiting formulation is as follows:

PG 64-22 asphalt binder=94.0% m/m

-   -   Hydrogreen Rejuvenator=can be optionally 0.2% m/m to 2.5% m/m         depending on requirements and climatic conditions where used.         Wherein, such requirement may be for example, a performance         requirement such as bond strength.     -   Additive can be 5% m/m to 8% m/m depending on base asphalt         quality and climatic conditions where used. Wherein asphalt         quality would mean that softer asphalts will require higher         levels of additive. As for climatic condition, in cold climates         the additive will be required at higher levels to improve         adhesion onto the surface substrate and form an acceptable bond         strength.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of a warm mix additive. The high melt point of the additive excludes it from Warm Mix application temperatures below 250° F. However at and above 250° F., for Warm Mix benefits the same effect and benefits in Viscosity, Lubricity and Adhesion are achieved. Further there is a need in the Industry for a Compaction aid for stiff binders and stiff mixes such as Ground Tire Rubber Modified binders, highly Polymer Modified binders and stiff mixes and the Additive is a perfect compaction agent at these temperatures employed and functions as a compaction temperature reduction and workability agent above 250° F. Also, by reengineering such highly modified Ground Tire Rubber and Polymer Modified Binders, the Grade Bump effect can be utilized to reduce the Ground Tire Rubber and Polymer levels while achieving the equivalent PG Grade with lower viscosity coupled with the “slip” effect for superior compaction.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of polymer modified asphalt (“PMA”). The additive may be combined with any asphalt modification polymer (SBS, SB, SBR, EVA, Elvaloy, PP, PE, APP, etc. to:

-   -   (a) Impart Warm Mix properties     -   (b) Reduce polymer content     -   (c) Reduce Mean Phase Angle     -   (d) UV Light Shield     -   (e) Increase Stiffness Modulus

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of ground tire rubber modified asphalt binders, and aids in the dispersion of ground tire rubber, and provides reduced viscosity, increased stiffness modulus, greater adhesion, enhanced ductility, and enhanced flexibility.

The adhesive chemistry derived from the additive's amine functionality, the reduced spray out viscosity and the rapid set time are unique benefits to be employed in the following applications:

-   -   Hot Applied Seal Coats     -   Hot Applied Chip Seals     -   Emulsion Seal Coats     -   Emulsion Chip Seals

Further the pool of suitable asphalt binders is substantially expanded by the availability of the additive for such applications and products.

The hydrogenated and aminated vegetable oil(s) function as a dispersion agent for polymers through co-extrusion eliminating need for high shear. Co-Extrusion of the additive with polymers difficult to disperse into asphalt binder (eg. SB, SBS, SBR, PP, HIPS, PTFE, etc) renders such polymers easily dispersible in asphalt binders with simple mixing and pump circulation and eliminates the need for expensive high shear mixers. This concept makes it possible for small producers and “poor” countries to produce polymer modified asphalt binders without need for such expansive high shear mixers, which are very expensive. Incorporation at 1% to 10% levels as needed into such polymers/polymer mixes will act as an anti-block agent, flow agent and dispersion agent.

The hydrogenated and aminated vegetable oil(s) functions as an anti-blocking aid/processing aid for the grinding of softer polymers and waxes for incorporation into asphalt and for Industrial applications. This benefit is derived from the high melt point as well as the high oil absorbing and retention power of the additive. Incorporation at 1% to 10% levels as needed into such polymers and polymer mixes will act as an anti-block agent, flow agent and dispersion agent.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of water-proofing and sealing applications. The combination of the additive with a safe aliphatic solvent (bio-diesel, soy methyl ester, etc) plus asphalt binder produces a controllable viscosity solvent paint that can be brushed on to surfaces as a waterproofing coating or protective coating against corrosion.

Use of the hydrogenated and aminated vegetable oil(s) eliminates the need for blowing asphalt binder and can produce blown asphalt grades of binder instantly by simple stirring in of the additive into refinery straight run asphalt grades such as PG 58-22, PG 58-28, PG 64-22, PG 67-22, VTB Bottoms, ROSE Bottoms, etc. Also, the additive can be added to standard refinery asphalts before blowing to reduce blow cycle times and/or added to partially blown asphalt grades to achieve final specifications through reduced blow cycle times.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production Asphalt Emulsion Paints and Coatings—undercarriage, pipe coatings, waterproofing, corrosion protection.

The hydrogenated and aminated vegetable oil(s), may be added to asphalt binder and then emulsified or emulsified first and then simply added to asphalt emulsions.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of asphalt solvent based paints and coatings—undercarriage, pipe coatings, waterproofing, corrosion protection. Paints include water based as well as solvent based paints. Examples of powder coatings include those household goods such as washing machines, clothes dryers, refrigerators, microwaves, etc. The present invention also finds utility with automotive coatings and which typically have composition comprising solvents, emulsifiers, surfactants, curing agents, fillers, drying agents, color pigments/dyes, etc.

Hydrogenated and aminated vegetable oil(s) are useful in the production of asphalt floor coatings for animal housing. The uric acid from animal urine is extremely corrosive to concrete flooring and a coating with an asphalt mixture (hot applied or emulsion applied) will act as a corrosion proof barrier on such floors. For example a composition of such a Hot Melt Adhesive will be one third by weight of Ethylene Vinyl Acetate (EVA) plus one third by weight Hydrogenated and Aminated Castor Oil plus one third by weight of Tackifier Resin. All the components are placed into a melting reactor and melted with heat and then pastillated into beads or extruded under water as tiny cylindrical particles and then packaged.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of asphalt hot melt glues, they may be formulated as ultra-high hot melt adhesive glue for aerospace and heavy duty applications. Benefits are extremely short set time with extremely high bond strength. As a non-limiting example, glue may refers to Hot Melt Adhesive glues (HMA) for all applications including Aero-Space, Construction, Automobiles and Industrial applications. Typically a non-limiting formulation for such an adhesive will be one third by weight of ethylene vinyl acetate (EVA) plus one third by weight of tackifier resin plus one third by weight of the additive of the present invention.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production Asphalt Hot Applied Roofing Coatings:

-   -   (a) Very Low Viscosity makes for ease and accuracy of         application.     -   (b) High Softening Point contributes to quick set and cure.     -   (c) Amine functionality enables excellent adhesion onto         substrates.     -   (d) Reduced hardening effect on Penetration Value contributes to         a flexible coating that will not crack with aging.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of asphalt emulsion roofing coatings, with the same benefits as noted above.

Hydrogenated and aminated vegetable oil(s) are useful in the production of color pigment dispersions. Color dispersants and dyes are difficult to disperse and a good wetting and dispersing agent is essential, and the additives of the present invention serve this function effectively to lower surface tension and enhance the dispersion. A typical composition may include fillers plus curing agents plus resins, plus drying agents plus dyes/pigments plus the additive of the present invention.

Their high melt point enables processing of pasty pigments and grinding at high throughput rates, with resulting excellent gloss and excellent color throw back/yield. Typically incorporation of the Hydrogenated and Aminated castor Oil will be at 1% to 10% by weight of the formulation and preferably at 2% to 5% level.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of corrosion protection coatings. They may be hot applied or emulsion applied for corrosion protection of all metal surfaces, with benefits including:

-   -   (a) Excellent adhesion from amine functionality.     -   (b) Low viscosity for application.     -   (c) High Gloss     -   (d) Flexibility against cracking in cold weather and/or with         aging.     -   (e) High Strength from high softening point.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the pelletization of asphalt and similar soft and tacky materials and heat melt sensitive materials eg. TLA, SBR, PE, soft petroleum waxes, etc. Benefits derived from high oil absorbency and retention, high melt point for absorbing heat of friction on grinding, anti-block properties during storage and handling.

Asphalts with hydrogenated and aminated vegetable oil(s) are useful in the production of crack sealants. As non-limiting example, insulating and water-proofing sealants and crack sealants such as for applications in windows, doors, cracks in areas including flooring, etc. Typical composition of such formulations will be drying agents, resins, fillers, solvents, polymers, asphalt, etc:

-   -   (a) Low viscosity ensures good wetting and penetration into         cracks.     -   (b) Amine functionality ensures excellent adhesive strength onto         substrate.     -   (c) High softening point ensures stiffness modulus and         cohesiveness in hot weather.     -   (d) Flexibility mitigates against cracking in cold weather.     -   (e) Relative High Penetration mitigates against cracking in cold         climates and/or through aging.

Hydrogenated and aminated vegetable oil(s) are useful in the production of thermal transfer inks, that is, they are utilized as a component of thermal transfer inks. Non-limiting examples will include bar coding inks where the bar code is thermally transferred from clear film onto paper/label substrates thermally to produce a sharp and clear bar code to be easily readable by the scanning machines. Examples of such formulation swill be resin plus color pigment plus clearing agents plus fillers plus the Additive. Typical incorporation levels will be 1% to 10% and preferably at 25 to 4%, and provides the following benefits:

-   -   (a) High Melt point provides good rub resistance and         anti-scuffing and enables high speed printing.     -   (b) High gloss     -   (c) Excellent adhesion onto substrates.     -   (d) Contributes to high color throw back/yield.     -   (e) Low viscosity for accuracy of application.     -   (f) Low viscosity enables higher filler/pigment loadings.     -   (g) Narrow cut versions available important for sharp definition         applications such as for bar coding.

Hydrogenated and aminated vegetable oil(s) are useful in the production printing Inks, with benefits as noted above. The printing Inks may be either solvent based or emulsion based and for all printing ink applications. Typically solvent based inks are a combination of a suitable solvent (or solvent mixture) plus color pigment and/or dyes, resins, surfactants, curing agents, drying agents plus the additive of the present invention. Emulsion based inks include all of the above plus surfactants/emulsifiers plus water as the carrier medium. Typically incorporated at 1% to 5% level by weight of the formulation for the claimed functionality.

Hydrogenated and aminated vegetable oil(s) are useful in the production of PVC compounds and PVC extrusion and molding. Multi-branched chain on one end of molecule provides good strength whilst amine functionality at opposite end provides excellent adhesive strength. Also, multi-chain hydrocarbon end provides good external lubricating effect whilst amine functionality provides good internal lubrication making this unique as combined external/internal PVC lubricant. Typically incorporated at level of 1% to 5% of the formulation for claimed functionality.

Hydrogenated and aminated vegetable oil(s) are useful in the production of PE compounds and PE molding, and enables higher filler loading higher impact strength and excellent gloss and mold release lubrication. Typically incorporated at level of 1% to 5% by weight of the formulation for claimed functionality.

The Key Benefits To Asphalt Users and Producers of such hydrogenated and aminated vegetable oil(s) additives is that it makes it possible to use a much wider source and range of asphalt binders until now considered “unsuitable” for roofing, paving and industrial applications. Also provides a reduction in polymer content of highly modified Polymer Modified Asphalt (greater than 4% Polymer) whilst delivering same or higher benefits of such highly modified systems. The resulting benefits of such produced PMA are increased stiffness modulus, lower viscosity, lower Mean Phase Angle, and enhanced adhesion to substrate.

EXAMPLES

The following non-limiting example are being provided merely to illustrate some non-limiting embodiments of the present invention. They are not intended to and do not limit the scope of the claims. In these examples, hydrogenated castor oil is produced by the addition of excess hydrogen to castor oil (hydrogenation process) in the presence of a nickel catalyst. This is done by bubbling hydrogen gas into the castor oil during which process the ricinoleic acid becomes fully saturated to produce a viscous waxy like substance with a melt point of 61° C. to 90° C. depending on the severity of the hydrogenation conditions.

High catalyst concentration and reaction in an autoclave is required to produce a deeply hydrogenated product with a melt range of 85° C. to 95° C. A temperature range of 125° C. to 135° C. as well as a pressure range of 2 to 2.5 kg/cm3 is required for the saturation of the double bonds.

The amination of the hydrogenated castor oil is carried out using a 1:1 mole ratio of diethanolamine plus deeply hydrogenated castor oil with sodium hydroxide pellets (0.2% to 0.5% range) as catalyst (or other suitable catalyst). The reaction is carried out under reflux conditions and a reaction temperature of 160° C. to 175° C. for 2 hours. The process may be optimized by using a reaction temperature in the lower part of the range with longer reaction times.

Depending upon the purity of the materials used, the mole ratio of diethanolamine: hydrogenated castor oil may be optimized around the 1:1 mole ratio to produce the desired melt point of the final hydrogenated aminated wax. This mole ratio produces a hydrogenated aminated wax in the melt point range of 135° C. to 145° C. However, any melt point in the range of 80° C. to 145° C. and higher may be produced eg. by increasing the diethanolamine mole ratio lower melt point hydrogenated aminated waxes are produced and by reducing the Diethanolamine mole ratio, higher melt point hydrogenated aminated waxes are produced.

Example 1

Bond Strength Evaluation of DOT™ C10 and DOT™ C12 Tack Coat

Bond strength testing was conducted for each tack coat sample at two different application rates and substrate conditions. The substrate conditions represented both milled and unmilled surfaces. Three replicates were prepared for each combination, for a total of 24 samples tested.

General Procedure. A single, 9.5 mm nominal maximum aggregate size (NMAS) Superpave mix developed by Basic Construction Company, LLC, located in Newport News, Va., was used as the surface mix for all samples tested. The mix design contained 35 percent recycled asphalt pavement (RAP), and had an optimum asphalt content of 5.55 percent. For the substrate samples, both milled and unmilled samples were used. The unmilled samples were prepared using a 12.5 mm NMAS Superpave mix designed to meet Alabama Department of Transportation's (ALDOT) 424 Specifications. The optimum asphalt content for the mixture was 4.6 percent. For the DOT™ C10 and DOT™ C12 tack coat samples, application rates of 0.08 and 0.13 gallons/square yard were evaluated. For a six inch gyratory sample and using a density of 8.6 pounds/gallon for the tack coat, this equated to applying 6.8 grams and 11.1 grams to the substrate surfaces, respectively.

For the milled samples, the substrate samples were from milled slab samples of a gravel based asphalt mix that the National Center for Asphalt Technology had extra from a research project and allowed us to obtain and use for this evaluation. Summaries of the job mix formulas used in this evaluation are presented in the Appendix. The job mix formula for the milled samples was not obtained.

For the unmilled substrate samples, a thickness of 63.5 mm was used; this is a typical lift thickness for a 12.5 mm NMAS asphalt mix. For the surface mix, a thickness of 38.1 mm was used for all samples. Therefore, samples were fabricated to a consistent height of 101.6 mm. During fabrication of the test samples, it was noticed that the milled samples had slight differences in thickness; therefore the samples could not be fabricated to a consistent height. It was decided that for the milled surfaces, the surface mix would be compacted using 10 gyrations, which was the average number of gyrations the surface mix needed to reach 101.6 mm for the unmilled samples. This allowed all samples to have approximately the same compaction effort applied to the surface mixture. Examples of the milled (right) and unmilled (left) substrate samples are shown in FIG. 1. FIGS. 2 and 2 show the tacked substrate samples at the 0.08 gallon/square yard application rate (FIG. 2) and the visual difference between the tack coat application rates when applied to the milled substrate samples (FIG. 3).

Tack Coat Bond Strength

Bond strength 12 testing was conducted according to ALDOT 430. The breaking head is pictured in FIG. 4. Measured data from the bond strength testing is presented in Table 1. From the data, several observations could be made. First, both tack coats produced bond strength values well above the recommended ALDOT minimum value of 100 psi. Second, the DOT C12 tack coat produced bond strength values greater than those measured for the DOT C10 tack coat. And third, the unmilled substrate samples had higher bond strength values that the milled substrate samples for each tack coat application rate.

For the milled substrate samples for the DOT C12 tack coat, each sample for the two application rates were tested at a different mill direction orientation. This was done to determine if mill direction had an influence on the measured bond strength. For the 0.08 gallon/square yard application rate, as the orientation angle increased, the measured bond strength increased. For the 0.13 gallon/square yard application rate, this trend was reversed. This may be due to the higher application rate creating a slight slippage plane across the milled grooves, lowering the measured bond strength. FIGS. 5 and 6 illustrate the bond strength samples after testing.

As used herein, Tack Type “Com '455” refers to a commercially available product based on U.S. Patent Publication No. 2011/0206455. Com '455 is a polymer modified asphalt having a pen value less than 50. Because the bond strength data in the '455 Publication was obtained using the University of Louisiana method, it was redone on commercial samples utilizing the Alabama DOT method described above so as to be consistent.

The Com '455 samples will have a much higher bond strength because it is based on Hard Pen asphalt with lower Pen values than the DOT 10 and DOT 12 samples. The higher bond strength is not necessarily better since the bond becomes too rigid and will not move/give way under traffic loading and temperature sweeps (warm to cold eg summer/winter and cold front weather). Therefore the products of the present invention will give more movement and will actually be better. The aminated Wax is also key difference, ie being functionalized wax it has active adhesion points for binder and pavement. Further it reduces the tack coat viscosity making it more penetrating and wetting out the substrate in addition to making the application easier and more controlled without stringing and pasting up.

TABLE 1 COMPOSITIONS OF DOT-C10 AND DOT-C12 DOT-C10 DOT-C12 Component % wt/wt % wt/wt Asphalt 93.00 93.00 Binder PG 64-22 Aminated 6.00 5.00 Wax, eg EcoGreen SPA Rejuvenator, eg 1.00 1.00 Hydrogreen Elastomeric 1.00 Polymer, eg Elvaloy Total % 100.00 100.00 Composition Notes for TABLE 1. 1. The Asphalt Binder PG 64-22 is a straight run asphalt binder with Pen value of 60 and softer (i.e., higher Pen values). No need for hard Pen binder. 2. The Aminated Wax is an aminated vegetable wax (castor oil) with a Softening Point of 250 F. and above. 3. The Hydrogreen Rejuvenator comprises tall oil and keeps formation of asphaltenes in check ie reduces the hardening/cracking propensity of the binder by retarding binder aging to maintain bond strength of the Tack Coat during life of pavement. 4. The Elastomeric Polymer is a ter-polymer or SBS polymer that balances the Ductility of the aminated wax with rigidity to provide a balanced movement of the pavement surface and retraction to mitigate against surface cracking.

One of the considerations in the development of the DOT-C Technology Tack Coat concept is the ability for any simple Aggregate Mixing Plant or simple Asphalt Blending Plant to produce the Tack Coat without the need for expensive and sophisticated equipment such as High Shear Siefer Mills and which costs in excess of 0.75 million USD to install. Ultrabond needs such high cost equipment and therefore cannot be produced at remote locations or by smaller contractors.

The primary function of a Tack Coat is to bond the old pavement substrate with the newly paved overlay aggregate mixture and prevent delamination due to fatigue from traffic loadings and temperature cycling. A secondary function is for the Tack Coat to perform as a membrane layer to permit flexibility and mitigate against cracking as well as prevent water permeation into the pavement and which is necessary to prevent the stripping of the lower pavement layer and cracking with freezing as the entrapped water expands upon turning into ice.

DOT-C10 Tack Coat and DOTC-12 Tack Coat

-   -   DOT-C10 Tack Coat is based upon the DOT-C10 asphalt formulation         shown above comprising Base Binder PG 64-22 plus Hydrogreen S         Rejuvenator plus Aminated Wax and all of are instantly         miscible/soluble at 150° C./302° F. with simple stirring and         pump circulation. This formulation is suited to those geographic         regions that are not susceptible to low ambient temperatures         such as the Southern USA States. As can be seen from the Table         of Properties, this formulation has all of the performance         properties required for ease of application as well as superior         performance.     -   DOT-C12 Tack Coat is based upon the DOT-C12 asphalt formulation         shown above that includes an Elastomeric Polymer that disperses         into the asphalt binder without the need for the expensive High         Shear milling equipment. The logic for this inclusion is to         design the Tack Coat to deliver the desired increased         flexibility needed for much colder geographic regions such as         the Northern USA states and Alaska where extreme low         temperatures require a higher level of flexibility.

TABLE 2 Measured Asphalt Bond Strength Data Average Sample Sample Mill Max Bond Bond Tack Diameter, Area, Orientation, Load, Strength, Strength, Type Surface Rate in in{circumflex over ( )}2 ° lbs psi psi C10 Unmilled 0.08 5.90 27.33 — 6300 230.5 230.0 5.90 27.32 — 5600 205.0 5.90 27.30 — 6950 254.6 0.13 5.90 27.33 — 6600 241.5 236.2 5.90 27.35 — 6075 222.1 5.90 27.34 — 6700 245.1 C10 Milled 0.08 5.90 27.31 — 5525 202.3 224.7 5.89 27.28 — 6350 232.7 5.90 27.30 — 6525 239.0 0.13 5.90 27.33 — 5175 189.3 193.1 5.90 27.31 — 5750 210.5 5.90 27.29 — 4900 179.5 C12 Unmilled 0.08 5.90 27.31 — 7675 281.0 281.0 5.90 27.31 — 8050 294.7 5.90 27.31 — 7300 267.3 0.13 5.90 27.34 — 8175 299.0 273.8 5.90 27.33 — 7775 284.5 5.90 27.33 — 6500 237.8 C12 Milled 0.08 5.90 27.34 0 5800 212.1 255.5 5.90 27.32 45 7400 270.9 5.90 27.34 90 7750 283.5 0.13 5.90 27.33 0 7250 265.3 245.3 5.90 27.29 45 6525 239.1 5.90 27.32 90 6325 231.5 Com Unmilled 0.08 5.90 27.36 — 10000 365.5 360.7 ′455 5.90 27.35 — 10000 365.6 5.90 27.36 — 9600 350.9 0.13 5.90 27.33 — 10000 365.9 366.1 5.90 27.30 — 10000 366.3 5.90 27.32 — 10000 366.0 Com Milled 0.08 5.90 27.35 0 10000 365.6 343.8 ′455 5.90 27.29 45 8175 299.5 5.90 27.30 90 10000 366.3 0.13 5.90 27.35 0 9900 362.0 345.4 5.90 27.31 45 8425 308.5 5.90 27.34 90 10000 365.8

Table 2 provides the Bond Strength data set comparing DOT-C10 and DOT-C12 with Com '455 and the following points are pertinent and relevant to the data presented:

-   -   1. The minimum Bond Strength per Alabama DOT method ALDOT 430 is         100 psi and which minimum value is exceeded by far for both         milled and un-milled surfaces for DOT-C10, DOT-C12 and Com '455.     -   2. In all cases the differential between the milled and         un-milled surface Bond Strengths is about the same and this         signifies that the surface texture plays a dominant role in the         value of the Bond Strength. The un-milled surfaces being         relatively smoother have a more even coating of the Tack Coat         and therefore more available surface contact points at the mix         substrate interfaces and for this reason will have a higher Bond         Strength as to be expected.     -   3. High Bond strength, up to a point is good for adhesion over         the life of the pavement and endured traffic load and         temperature fatigue cycles. However, a degree of flexibility in         the Bond is essential to permit some pliability and movement         under such pavement fatigue stresses and strains described         above. If such flexibility is not present the Tack Coat bond         will crack and the integrity of the pavement will be compromised         and it will fail prematurely. Therefore extremely high Bond         Strengths such as that exhibited by the Com '455 being too         brittle will crack and work against the concept of bonding and         rather cause pavement failure.

TABLE 3 Drive On Tack Coat (DOT-C) SUMMARY OF RESULTS DOT- DOT- COM Property Test Method C10 C12 ′455 Rotational viscosity at AASHTO 137.50 212.50 735.5 150° C./302° F., cps T316 Rotational Viscosity at AASHTO 100.00 162.50 475 160°/320° F., cps T316 Softening Point, ° C./° F. ASTM 264.7/ 264.1/ 194.5/ D3104 129.3 128.9 90.3 Ductility at 25° C., cm ASTM 90 39 0 D113-07 Elastic Recovery at 25° C., % AASHTO 17.5 15 0 T301 Needle Penetration at 25° C., AASHTO 35 30 9 1/10 mm (for the tack coat) T49 Needle Penetration at 25° C., 65 65 1/10 mm (for the Base Asphalt PG 64-22)

This TABLE 3 provides results for various testing on the three Tack Coats.

Example 2

This example shows the effect of additive on softening point and Pen value of PG 67-22 asphalt binder. Results are shown in Table 4 of FIG. 7.

As shown by the data, with the additive of the present invention, there is a steep increase in Softening Point without need for blowing. As an improvement of the additive over blowing, there is no oxidative aging of binder as in blowing. Also, use of the additive of the present invention results in less than 10% of batch cycle time compared to blowing. Further, use of the additive of the present invention results in more than 10 times production volume compared to blowing. As an advantage, use of the additive of the present invention may be with standard production equipment. Finally, use of the additive of the present invention results in moderate decrease in Pen value unlike blowing or hard wax additives such as Fischer-Tropsch Waxes.

Example 3

This example shows use of the additive of the present invention in the production of BUR Roofing Grades from standard refinery asphalt streams and demonstrates that blowing is not necessary. The results are shown in Table 5 of FIG. 8.

As shown, use of the additives of the preset invention makes it possible to use a wider range of refinery asphalt binder streams thus resulting in a more varied supply flexibility. Use of the additives of the present invention, eliminates blowing associated pollution/emissions, energy consumption, long batch cycle times, higher viscosity of binder and formation of carcinogenic components resultant from blowing. Also, use of the additives of the present invention substantially enhance operational safety as the binder may be handled at lower temperatures.

Example 4

This example demonstrates the use of hydrogenated and aminated castor wax to produce built-up-roofing grades or binders and thus eliminating the need for blowing asphalt. Results are shown in Table 6 of FIG. 9.

Note, “Zero” Pen is deeply vacuumed bottoms produced by different refining methods and has Pen typically in range of 5 to 15. This is an example of how a greater pool of Refinery binder streams may be usefully employed to produce Roofing Grades. This example reinforces the point that some embodiments of the additive of the present invention eliminate the need for blowing asphalt. Using the additive of the present invention, roofing binders will utilize lower polymer (SBS, SBR, etc.) levels. Using the additive of the present invention roofing binders can be produced and handled at lower temperatures due to the substantially reduced viscosity imparted by the additive.

Example 5

This example shows results for the reduction in blow time evaluation of 60%, 70% and 80% blown binders plus additives—filled and unfilled coatings evaluation. Results are presented in Table 7 of FIG. 10.

Example 6

This example evaluated the performance of the use of hydrogenated and aminated castor oil wax in roofing shingles coatings. Results are provided in Table 8 of FIG. 11.

Example 7

The example demonstrates the effect of the additive of the present invention on PG Grade Bump, Viscosity Reduction above 270° as well as as Compaction Aid for Stiff and High Viscosity Mixes. Results are provided in Table 9 of FIG. 12.

The viscosity decrease with the additive of the present invention is small in magnitude but relevant especially considering that it causes a Grade Bump effect to next grade for which viscosity should have been even higher. In the case of the PG 76-22 plus Additive it demonstrates that a PG 88-22 can be compacted at the same temperature as a PG 76-22 ie Warm Mix effect. For PG 64-22 the additive of the present invention provides a Grade Bump close to 1 Grade. For PG 67-22 the additive of the present invention provides a Grade Bump of more than half Grade. For PG 76-22 the additive of the present invention provides a Grade Bump of over 1 Grade and SBS can be reduced to get even lower viscosity.

Example 8

This example demonstrates that the just the deeply hydrogenated castor oil will not produce the same effect in asphalt binder as the deeply hydrogenated castor oil that is also aminated. Results are provided in Table 10 of FIG. 13.

While the viscosity of 1,200 at first glance appears to be high relative to the neat PG 64-22 binder and 2% HCO binder, on further analysis it is a relatively low viscosity for an asphalt with such a high softening point as 210.9° F.

Example 9

This example demonstrates the UV light stability enhancing effect of the hydrogenated and aminated castor oil. Results are provided in Table 11 of FIG. 14. Notice that there is significant reduction in surface cracking with the additive. Further, initial surface cracks formed that appear to be mended over time with the additive.

Example 10

This example also demonstrates the UV light stability enhancing effect of the hydrogenated and aminated castor oil. Results are provided in Table 12 of FIG. 15. Notice there is a reduction in hairline cracks with the additive. Further, the blown binder UV light stability is superior to straight run binder, but blowing can be eliminated by additive usage.

Example 11

This example shows Tensile Strength Ratio (TSR) for a control and samples with 0.5% and 1% additive of the present invention conducted according to Test Method AASHTO T283. As shown by the data, the addition of the additive provides active adhesion of binder onto aggregate surfaces. Results are provided in Table 13 of FIG. 16. Notice that the TSR of the control sample is 0.554 vs TSR of additive into same control binder at 0.5% level is 0.979 vs TSR of additive into same control sample at 1% level is 0.958. More important is that the additive improves the Wet Strength from 96.05 psi to 171.03 psi (at 0.5% level) and to 165.07 (at 1% level) proving active adhesion.

Finally, all articles, books, information, journals, magazines, materials, newsletters, newsletters, online materials, patent applications, patent publications, periodicals, publications, texts, and treatises, and/or any other type of publication, cited in this application are herein incorporated by reference in their entirety as if each individual reference was specifically and individually set forth herein. It should be understood that incorporated information is as much a part of the application as filed as if the information was repeated in the application, and should be treated as part of the text of the application as filed.

While the present invention has been described as being useful for creating a bonded friction course pavement, it should be understood that the compositions, products and methods of the present invention may be useful in any form of pavement not just bonded friction course pavement. The present invention may find utility for any type of asphalt application such as roads, runways, athletic tracks, speedway tracks, parking lots, roofing surfaces, driveways, playground surfaces, sports surfaces, and the like, be it as the top surface layer, or as a below surface layer. The present invention may also be useful for creating a water-proof barrier between zones or around certain objects.

While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains. 

1. An asphalt composition comprising a hydrogenated and aminated vegetable oil and an asphalt.
 2. The composition of claim 1 further comprising aggregate.
 3. The composition of claim 1, wherein the vegetable oil is castor oil.
 4. The composition of claim 3 further comprising aggregate.
 5. A method of making an asphalt composition comprising contacting an asphalt with a hydrogenated and aminated vegetable oil.
 6. The method of claim 5 wherein aggregate is included in the composition.
 7. The method of claim 5, wherein the vegetable oil comprises castor oil.
 8. The method of claim 7 wherein aggregate is included in the composition.
 9. A pavement structure comprising: a substrate pavement layer; and, a tack coat applied to the substrate pavement layer, wherein the tack coat comprises an asphalt and a hydrogenated and aminated vegetable oil.
 10. The pavement structure of claim 9, wherein the vegetable oil comprises castor oil.
 11. A pavement structure comprising: At least one layer comprising asphalt and a hydrogenated and aminated vegetable oil.
 12. The pavement structure of claim 11 wherein the at least one layer further comprises aggregate.
 13. The pavement structure of claim 11, where the vegetable oil is castor oil.
 14. The pavement structure of claim 13 wherein the at least one layer further comprises aggregate.
 15. A roofing shingle comprising asphalt and a hydrogenated and aminated vegetable oil.
 16. The shingle of claim 15 wherein the vegetable oil is castor oil.
 17. A method of sealing a surface, comprising applying to the surface a sealant comprising asphalt and a hydrogenated and aminated vegetable oil.
 18. The method of claim 17 wherein the vegetable oil comprises castor oil.
 19. A method of forming a blown asphalt, the method comprising: Providing an asphalt mixture comprising asphalt and a hydrogenated and aminated vegetable oil; and, Blowing the asphalt mixture to form blown asphalt.
 20. The method of claim 19, wherein the vegetable oil is castor oil.
 21. A method of pelletizing asphalt, the method comprising: Providing an asphalt mixture comprising asphalt and a hydrogenated and aminated vegetable oil; and, Pelletizing the asphalt mixture to form asphalt pellets.
 22. The method of claim 23, wherein the vegetable oil comprises castor oil. 